INTEGRATED MIXING DEVICE (IMD) INSTALLATION AND OPERATING INSTRUCTION MANUAL For your family’s comfort, safety and convenience, it is recommended this IMD be installed and serviced by a plumbing professional. CAUTION If sweat fittings are to be used, DO NOT apply heat to the fittings on top of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water connections. It is necessary that heat is not applied to the fittings to ensure appropriate operation. This manual will explain in detail the installation and maintenance of the integrated mixing device. We require that you carefully read this manual and refer to it if questions arise. PRE-INSTALLATION The following steps should be taken to ensure proper conditions for operation: Note all site parameters (pressure, temperature, etc.) and check against the integrated mixing device (IMD) specifications listed in Table 1. All specifications must be met prior to installing the IMD. This IMD MUST NOT be subjected to heat during installation as this may damage the internal parts. The valve MUST NOT be allowed to freeze. If the IMD is installed in a potentially freezing situation, suitable insulation must be fitted to prevent damage. DO NOT use excess thread sealant (in liquid, tape or other form) as this may cause the IMD to fail. The installer must ensure that thread sealant does not get into the internal parts. In order to install this IMD on a unit with a blower mounted on top, it is necessary to remove the blower prior to installation and replace the blower after installation of this IMD, or purchase an optional nipple extender kit, p/n 239-48429-00. See Step 2a(Figure 5a) and Step 3a(Figure 6a). If the water heater is gas-fired, the IMD must be installed before the draft hood. This manual is meant to be used in conjunction with the installation and operation manual (owners manual) for the water heater. Toxic chemicals, such as used for boiler treatment, shall not be introduced into IMD used for space heating. This IMD may never be connected to any existing heating system or component(s) previously used with a non-potable water heating system. Leave a copy of this instruction manual with the water heater for future reference. Recommend to the user that the IMD be checked annually to ensure its continued function. Page 1 238-47870-00E 07/10
Transcript
INTEGRATED MIXING DEVICE (IMD)INSTALLATION AND OPERATING INSTRUCTION MANUAL
For your family’s comfort, safety and convenience, it isrecommended this IMD be installed and serviced by a plumbingprofessional.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the fittingson top of the water heater. Sweat the tubing to the adapter beforefitting the adapter to the water connections. It is necessary thatheat is not applied to the fittings to ensure appropriate operation.
This manual will explain in detail the installation and maintenance of the integratedmixing device. We require that you carefully read this manual and refer to it ifquestions arise.
PRE-INSTALLATION
The following steps should be taken to ensure proper conditions for operation:Note all site parameters (pressure, temperature, etc.) and check against theintegrated mixing device (IMD) specifications listed in Table 1. Allspecifications must be met prior to installing the IMD.This IMD MUST NOT be subjected to heat during installation as this maydamage the internal parts.
The valve MUST NOT be allowed to freeze. If the IMD is installed in apotentially freezing situation, suitable insulation must be fitted to preventdamage.DO NOT use excess thread sealant (in liquid, tape or other form) as this maycause the IMD to fail. The installer must ensure that thread sealant does notget into the internal parts.In order to install this IMD on a unit with a blower mounted on top, it isnecessary to remove the blower prior to installation and replace the blowerafter installation of this IMD, or purchase an optional nipple extender kit, p/n239-48429-00. See Step 2a(Figure 5a) and Step 3a(Figure 6a).If the water heater is gas-fired, the IMD must be installed before the draft hood.This manual is meant to be used in conjunction with the installation andoperation manual (owners manual) for the water heater.Toxic chemicals, such as used for boiler treatment, shall not be introduced intoIMD used for space heating. This IMD may never be connected to any existingheating system or component(s) previously used with a non-potable waterheating system.
Leave a copy of this instruction manual with the water heater for future reference.
Recommend to the user that the IMD be checked annually to ensure itscontinued function.
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Mixed water supply temperature range
INTEGRATED MIXING DEVICE - IMD SPECIFICATIONS
100 - 145°F (38 - 63°C)
Water heater outlet temperature range 100 - 180°F (38 - 82°C)
Temperature differential(between hot supply and outlet temperature)
Device temperature stability (nominal)
± 3°F (± 1.7°C) at 3 - 5 gpm (see note 1)± 5°F (± 3.0°C) at 5 - 40 gpm (see note 1)
Cold water inlet temperature range 33 - 80°F (1 - 27°C)
Hydrostatic pressure 150 psi (1034 kPa) maximum
27°F (15°C) (see note 2)
± 10% (see note 3)
0.25 gpm (0.9 L/m)
19.2 gpm (72.0 L/m)
2.8 (mixed temp. of 95°F)(35°C)1.8 (mixed temp. of 120°F)(49°C)1.3 (mixed temp. of 140°F)(60°C)
Permitted supply pressure variation
Flow rate (min)
Flow rate (max)
Cv
Notes:1. As tested in accordance with ASSE 1017.2. This is the minimum difference required between the mixed water supply
temperature and the water heater outlet temperature to enable the IMD to function correctly and ensure shut-off of outlet flow in the event of cold supply failure.
3. Maximum permitted variation in either supply pressure in order to control the mixed water supply temperature to within ± 3°F. Excessive changes in supply pressures may cause changes in mixed water supply temperature.
Mixed TemperatureMixed Temperatureof 140°F(60°C) of 120°F(49°C)
of 95°F(35°C)
Remove all components from thepackage and check that all requiredcomponents are included. The requiredcomponents are: mixing device, coldwater tee, flexible metal connector andthermostrip (see Figure 1).
This kit may have two flexibleconnectors provided for water heaterswith top water course connections at 8inch and 11 inch spacing. Use theappropriate flexible metal connector.
The mixing device, cold water tee, flexible metal connector and thermostrip areintegral parts of the water heater. This system improves hot water deliverability andmust be installed. The integrated appliance is designed for a maximum workingpressure of 150 p.s.i. (1034 kPa). Refer to the “Water Connections” section of theinstallation and operation instruction manual supplied with the water heater foradditional instructions.
WATER CONNECTIONS
The mixing device is equipped with a ½” NPT alternate hot water outlet that drawsunmixed very hot water from the tank. This outlet should be used if unmixed veryhot water is needed at specific fixtures (laundry, dishwasher, etc…). It is alsoequipped with a ½” NPT optional recirculation inlet that must be utilized inconjunction with a check valve if a recirculation loop is used (see Figure 2).
WARNINGIf recirculation loop water is returned to the water heater at anylocation other than the optional recirculation inlet, unmixed veryhot water is exposed to the recirculation loop. Do not returnrecirculation loop to any other location other than “R” inlet of themixing device.
Mixing device
Flexible metalconnector
Cold watertee
Thermostrip
(AH) ½" NPT Alternatehot water outlet
(MIX) ¾" NPT Mixedwater outlet
(COLD) Cold water inlet fromcold water tee
(R) ½" NPT Optionalrecirculation inlet
(HOT) ¾" NPT Hot waterinlet from water heater
Figure 1IMD Components
Figure 2Mixing Device
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Instructions
The cold water tee is equipped with a ¼” NPT optional cold water outletthat draws cold water prior to the water heater (see Figure 3). This outletmay be used to connect cold water to refrigerator ice makers or other lowflow applications.
WATER CONNECTIONS CONTINUED...
¾" NPT Cold waterinletCold water outlet to mixing
device
¼" NPT Optional coldwater outlet ¾" NPT Cold water outlet
to water heater
ASSEMBLY PROCEDURE1. Twist and pull thread protectors with pliers or large regular screw driver toremove them from flexible metal connector as shown in Figure 4.
CAUTION
Do not damage flared connectors orthreads on connector nuts whenremoving thread protectors.
Flexible metalconnector
Figure 3Cold water Tee
Figure 4Flexible Metal Connector
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Flare connectors withthread protectors
2. Install the cold water tee onto the cold water inlet of the water heater. If installingon a water heater with 1" inlet fitting, use 1" NPT to ¾" NPT brass reducer bushingand brass nipples. Tighten until leak tight and facing the front of the water heater asshown in Figure 5.
ASSEMBLY PROCEDURE CONTINUED...
Cold water tee
Water heater coldwater inlet
Figure 5Installing Cold Water Tee
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2a. OPTIONAL INSTALLATION: Install the cold water tee onto the extension that isinstalled onto the cold water inlet of the water heater. If installing on a water heaterwith 1" inlet fitting, use 1" NPT to ¾" NPT brass reducer bushing and brass nipples.Tighten until leak tight and facing the front of the water heater as shown in Figure5a.
Cold water tee
Optional Extender
Front of waterheater
Figure 5aInstalling Cold Water Tee
with Optional Extender
Water Heater coldwater inlet
Front of waterheater
Mixing device
Water heater hotwater outlet
3. Install the mixing device onto the hot water outlet of the water heater. Ifinstalling on a water heater with 1" outlet fitting, use 1" NPT to ¾" NPT brassreducer bushing and brass nipples. Tighten until leak tight and facing the front ofthe water heater as shown in Figure 6.
3a. OPTIONAL INSTALLATION: Install the mixing device onto the extension that isinstalled onto the hot water outlet of the water heater. If installing on a water heaterwith 1" outlet fitting, use 1" NPT to ¾" NPT brass reducer bushing and brassnipples. Tighten until leak tight and facing the front of the water heater as shown inFigure 6a.
4. Install the flexible metal connector to the mixingdevice and cold water tee as shown in Figure 7.Tighten flare connectors until leak tight.
At this time the IMD should be leak tight. Continue installation of potable watersystem as indicated in the installation and operation instruction manual suppliedwith the water heater.Once potable water system has been completely installed, install the thermostrip onthe mixed water outlet pipe no more than 10 inches from mixing device as shown inFigure 8.
ASSEMBLY PROCEDURE CONTINUED...
Mixing deviceCold water tee
Flexible metalconnector
Figure 7Installing Flexible Metal Connector
(MIX) Mixed wateroutlet
Cold water inlet
Optional cold wateroutlet
Thermostrip
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Figure 8Installing Thermostrip
Flare connector
Check Valve
WARNINGIf recirculation loop water is returned to the water heater at anylocation other than the optional recirculation inlet, unmixed veryhot water is exposed to the recirculation loop. Do not returnrecirculation loop to any other location other than “R” inlet of themixing device.
IMD CARE AND MAINTENANCE
WARNINGSCALDING
This water heater can deliver scalding temperature water at any faucet inthe system. Be careful whenever using hot water to avoid scalding injury.By setting the thermostat on this water heater to obtain an increased watertemperature, you may create the potential for scald injury. To protectagainst injury, you should install an ASSE approved thermostatic mixingvalve (a device to limit the temperature of water to protect against scaldinjury via mixing hot and cold water supply) in the water system. Thisvalve will reduce point of discharge temperature in branch supply lines.This water heater was shipped with an ASSE approved thermostaticmixing valve. Install this valve according to the directions in the mixingdevice container. DO NOT OPERATE THIS WATER HEATER WITHOUT ANASSE APPROVED THERMOSTATIC MIXING DEVICE. If this water heaterwas shipped without an ASSE approved thermostatic mixing valve,contact the manufacturer.
TEMPERATURE ADJUSTMENTPrior to adjusting the IMD, the water heater must be operational and deliver hotwater within the Water Heater Outlet Temperature Range (100°F - 180°F) (38 -82°C). Note that the water heater thermostat is factory set at approximately 120°F(49°C) or lower. For proper operation, the temperature setting on the water heatermay be increased. Prior to measuring the Mixed Water Supply Temperature, allowthe water heater to recover from the thermostat adjustment.
Measure the Mixed Water Supply Temperature at the nearest faucet supplied bythe integrated mixing device. A flow rate of 1 to 1.5 gpm (4 to 6 L/min) isrecommended.
An accurate temperature measuring device such as a thermometer must be used toensure that a suitable temperature of mixed water is achieved.
Allow the water to run until a steady temperature is reached. The amount of timenecessary is dependant on the outlet's location to the water heater.
WARNINGHotter water increases the risk of scald injury. Scalding may occurwithin 5 seconds at a setting of 140°F (60°C). Water temperature over125°F (52°C) can cause burns or death from scalds. Children, disabledand the elderly are at highest risks of being scalded. Please feel thewater before bathing or showering.
120°F (49°C) More than 5 minutes125°F (52°C) 1 ½ to 2 minutes130°F (54°C) About 30 seconds
APPROXIMATETIME/TEMPERATURE
RELATIONSHIP IN SCALDS
135°F (57°C) About 10 seconds140°F (60°C) Less than 5 seconds145°F (63°C) Less than 3 seconds150°F (66°C) About 1 ½ seconds155°F (68°C) About 1 second
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Rotate counter clockwise toincrease mixed water
temperature
Rotate clockwise todecrease mixed water
temperature
TEMPERATURE ADJUSTMENT CONTINUED...1. The Mixed Water Supply Temperature may require adjustment. The IMD is setat approximately 120°F when the arrow on the hand wheel and the arrow on thecasting are aligned.
a. To Increase Mixed Water Supply Temperature: Depress and rotate the handwheel counter clockwise until the desired set point is reached (see Figure 9). Referto thermostrip temperature reading for desired set point (hot water must be flowingat a minimum of 1 gpm to accurately read thermostrip). Ensure the hand wheelsnaps back to the locked position once desired set point is reached.
b. To Decrease Mixed Water Supply Temperature: Depress and rotate the handwheel clockwise until the desired set point is reached (see Figure 9). Refer tothermostrip temperature reading for desired set point (hot water must be flowing ata minimum of 1 gpm to accurately read thermostrip). Ensure the hand wheel snapsback to the locked position once desired set point is reached.2. Verify that the desired set point is reached by allowing an appropriate amount ofwater to run from the nearest faucet supplied by the IMD.
CHECKING / SERVICING THIS DEVICEIt is recommended that the IMD is checked annually to ensure proper systemcapabilities. Where adverse water conditions are applied, more frequentintervals are recommended.
In checking the mixed water supply temperature, use the same faucet used inthe initial installation temperature adjustment.
There may be some variation in the water temperature from the IMD due toseasonal temperature variations in the cold water supply.
If the water supply is of poor quality, the internal components may jamrequiring an additional filter or strainer to be fitted to the system.Contact a plumbing professional for appropriate materials andinstallation.
Depress
Figure 9Adjusting Mixed Supply Temperature
Arrow on casting
Arrow on handwheel
Hand wheel
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RESIDENTIAL MODEL WITH HONEYWELL MIXINGDEVICE AND RETURN CIRCULATION
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Figure 10RECIRCULATION
SYSTEM
(Maximum trickle flow for the recirculating water is ¼ to ½ gpm.)
* EXPANSION TANKREQUIRED TOMINIMIZE ANYPRESSURE BUILDIF THE WATERSUPPLY PIPINGHAS A BACK-FLOWPREVENTER,CHECK VALVE ORWATER METERWITH A CHECKVALVE.
